Process for the in situ production of polyether polyols based on renewable materials and their use in the production of flexible polyurethane foams

Abstract

A polyether polyol based on renewable materials is obtained by the in situ production of a polyether from a hydroxyl group-containing vegetable oil, at least one alkylene oxide and a low molecular weight polyol having at least 2 hydroxyl groups. The polyol is produced by introducing the hydroxyl group-containing vegetable oil, a catalyst and an alkylene oxide to a reactor and initiating the alkoxylation reaction. After the alkoxylation reaction has begun but before the reaction has been 20% completed, the low molecular weight polyol having at least 2 hydroxyl groups is continuously introduced into the reactor. After the in situ made polyether polyol product having the desired molecular weight has been formed, the in situ made polyether polyol is removed from the reactor. These polyether polyols are particularly suitable for the production of flexible polyurethane foams.

Description

FIELD OF THE INVENTION[0001]The present invention relates in general to polyols useful for the production of polyurethanes, and more specifically, the production of flexible polyurethane foams, preferably, flexible, free-rise or slabstock polyurethane foams. These polyether polyols are produced by reacting an alkylene oxide, a low molecular weight polyol and a hydroxyl group-containing vegetable oil in the presence of an alkoxylation catalyst.[0002]As used herein, a “hydroxyl group-containing vegetable oil” is any fatty acid triglyceride derived from hydroxylated vegetable, animal or other natural sources having at least one hydroxyl group, preferably, from 2 to 6 hydroxyl groups, capable of being alkoxylated.BACKGROUND OF THE INVENTION[0003]Polyurethane foams have found extensive use in a multitude of industrial and consumer applications. This popularity is due to polyurethane's wide ranging mechanical properties and the excellent cushioning performance of the foamed product and it...

AI Technical Summary

Benefits of technology

The present invention provides technical effects that improve upon previous technologies. These effects may include increased efficiency, improved functionality, enhanced performance, or other advantages. These technical effects may be achieved through the use of innovative techniques, materials, or designs.

Problems solved by technology

Use of such polyester or polyether polyols contributes to the depletion of oil, which is a non-renewable resource.

Also, the production of a polyol requires the investment of a great deal of energy because the oil to make the polyol must be drilled, extracted and transported to a refinery where it is refined and processed to yield the finished polyol.

Unfortunately, the use of the petroleum-based products is a highly developed industry and years of optimization have created products tailored to meet strict industry requirements.

For example, although castor oil-based polyurethanes have been known for decades, their use has generally been limited to a few applications such as hydrophobic coatings and certain sealants where the typical polyurethane properties are not required.

However, production of foam articles that meet the foam processing and property requirements of petroleum based polyols using only a castor oil-based polyol has not yet been achieved.